The A to Z's of Microbial Control, Monitoring and Validation of Water Systems for Pharmaceuticals, Biologics, Medical Devices, Cosmetics, and Personal Care Products: 2-day In-person Seminar
T.C. Soli, President of Soli Pharma Solutions, Inc
San Francisco, CA
| Wednesday, March 8, 2017 | Thursday, March 9, 2017
| Thursday, June 15, 2017 | Friday, June 16, 2017
All facilities manufacturing pharmaceuticals, biologics, medical devices, cosmetics, and personal care products are likely to have high purity water systems. In spite of this purity, microorganisms can flourish within these systems and lead to undesirable contamination of facility processes and their products. Of all the individuals at the facility, it is site’s microbiologists who should understand the microorganisms in water systems and how best to monitor and control them. Sadly, this is often not the case due to the lack of familiarity with biofilm and its impact on water system sampling, testing, sanitization, and routine maintenance. This lack of understanding of microbial control often leads to poor system designs, poor system sampling, poor system maintenance and poor sanitization practices, and as a result, ongoing microbial problems with the water.
This course is designed to provide a microbiology-focused education about all aspects of water systems and how biofilm manages to thrive there. Prior microbiological education or training, though a plus, is not a requirement, since this training is for everyone involved with water systems, from the lab to utility room operations. The instructor will provide the necessary background needed to understand this very important subject matter. This understanding is essential for the proper design, validation, operation, monitoring, and maintenance of a high purity water system. Without this understanding, water system control and monitoring consists of a set of rules that often don’t work or result in erroneous monitoring data and can cause everything from very costly and unnecessary system downtime to patient injury and product recalls.
At the completion of the course, attendees will be able to:
- Understand the role of system design, maintenance and sanitization in controlling microbial levels in pharmaceutical water systems.
- Successfully troubleshoot problems resulting from poor design/maintenance versus sampling or testing problems.
- Devise water system validation protocols that truly validate microbial control.
- Validate their water microbial test method.
- Develop sound Alert and Action Levels and Water Specifications.
- Defend their test method, in-process control levels and specifications to FDA.
Who Will Benefit:
This 2-day course is particularly relevant to managers, supervisors, and operatives taking on new responsibilities related to water, but also for experienced water personnel to learn the “true” whys behind what they do and perhaps better ways of doing things. Specific positions that will benefit:
- Microbiology Laboratory supervisors and analysts responsible for water sampling and testing
- Quality Assurance personnel responsible for water system deviation management and change control
- Regulatory and Compliance professionals responsible for FDA interactions
- Process and Utility Engineers responsible for water system maintenance, troubleshooting, and excursion mitigation
- Facility Engineers responsible for water system design or renovation
- Validation personnel for water system qualification
Seminar Fee Includes:
USB with seminar presentation
Hard copy of presentation
$100 Gift Cert for next seminar
|Day One (8:30 AM – 4:30 PM)
||Day Two (8:30 AM – 4:30 PM)
Registration Process: 8:30 AM – 9:00 AM
Session Start Time: 9:00 AM
- Basics of Water System Biofilm Control by Design & Operation
- Understand biofilm basics and how it develops
- Understand the impact of biofilm on the commonly used purification unit operations
- Understand how various commonly used microbial control strategies work (or don’t work) to control biofilm development
- Understand the how, where, and why of microbial monitoring, action levels, etc.
- Debunk a few water system myths
- Get answers to your own water system questions
- Successful Water System Sanitization
- Material and construction limitations
- Continuous vs intermittent sanitization
- The importance of biofilm removal
- How sanitants work (or don’t work)
- When to sanitize
- Common causes for sanitization failures and troubleshooting sanitization problems
- Common Sense Water System Validation
- Why validate a water system?
- Basic ground rules for water systems before you validate them
- Minimum validation expectations
- Making changes to a validated water system
- Special considerations for lab water systems
- Are packaged waters a viable option?
- Understanding and Controlling Endotoxin
- Where does endotoxin come from?
- What are the properties of endotoxin ?
- How do you get rid of it?
- How do you detect it?
- What assay controls are used?
- What are the endotoxin specs for water?
- How do you control it?
- Harmonizing vs Optimizing Water Microbial Testing for System Quality Control
- Water harmonization that has occurred
- Water Micro TM “Dis-Harmonization”
- A little about Biofilm
- Biofilm diversity in water systems
- Micro TM options and evaluation protocol
- The good and bad of Micro harmonization
- Where RMMs can fit in
- Microbial Enumeration Issues with High Purity Water Systems
- Biofilm enumeration issues (planktonic vs surface)
- Traditional cultivative approach issues
- Validation of your test method
- Alternative TM choices (advantages/disadvantages)
- Significance of water isolates
- Sampling issues
- Establishing Alert/Action Levels and Water Specs and defending them to FDA
- Reducing Water Microbial Excursions & Improving Investigations
- What are excursions?
- Water system dilemma: process control or quality control (utility or raw material), or both
- Intended roles of Alert/Action Levels and Specifications
- Investigation, necessary and often fruitless
- Excursion responses and impact
- Criticality of valves, hoses, & outlet flushing
- Diagnosing the source of the problem
- Water System Investigation "How-To's" and Example Case Studies
- Gathering and assessing existing data and symptoms
- Considering user opinions
- Investigation approach elements
- Recognizing red herrings/false positives
- Recognizing possible root causes
- Water system contamination case studies
- Leadership in Mfg Contamination Control: The Microbiology Lab
- How contamination is controlled
- Why the microbiology lab should lead in contamination control
- Routine contamination evaluation activities
- Microbiological training
- Root cause and impact investigations
- Impediments to leadership
- Doing the right thing
- USP Chapter <1231> : What USP Says about PW, WFI, Pure Steam & Micro Issues
- PW, WFI, Pure Steam micro specifications?
- <1231> Starting water issues
- <1231> Misunderstood issues clarified
- <1231> Microbiological test issues clarified
- <1231> Suggested micro test method
- <1231> Micro Specifications
- <1231> Alert and Action Levels and max’s
- Recent/Upcoming USP water changes
- Discrepancies between pharmacopeias
- New water initiatives – need your input/feedback
- Guarding Against Common Pharmaceutical Water System Inspection Pitfalls
- Initial Deficiencies Usually Lead to Others
- Design and Construction Issues
- Source Water Issues
- Sampling Issues
- Validation Issues
- Change Control Issues
- Procedure Issues
- Specification Issues
- Excursion Investigation Issues
- Training Issues
Meet Your Instructor
President of Soli Pharma Solutions, Inc
T.C. Soli, Ph.D., is President of Soli Pharma Solutions, Inc, with training, auditing, and troubleshooting expertise covering water systems, sterilization, aseptic processing, contamination control, and microbiological laboratories. He has over 34 years of combined pharmaceutical experience as a consultant and with operating companies (DSM Pharmaceuticals, Glaxo Wellcome, Burroughs Wellcome, and Pfizer). Dr. Soli's career-long water system and manufacturing contamination troubleshooting expertise, coupled with water-related USP, ISPE, PhRMA, and PDA committee and guide creation involvements, afford him practical knowledge about process and contamination control and mitigation; cleaning, sterilization, process, and microbiological testing validation; and all aspects of high purity water systems.
Dr. Soli is in his third 5 year term on USP Expert Committees responsible for Pharmaceutical Water, previously served 5 years on the Advisory Panel to the USP Microbiology Subcommittee, and helped develop the Water Conductivity and TOC specifications used by USP and adopted world-wide. He has authored many articles and chapters in books and industry guides published by PDA and ISPE and is the author of USP’s Chapter <1231>.
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San Francisco, CA (Venue to be announced shortly)
March 8-9, 2017
Newark, NJ (Venue to be announced shortly)
June 15-16, 2017
San Francisco, CA, Local Attractions
Newark, NJ, Local Attractions
Think Escape Party Bus
San Francisco Bay Area
Board a luxurious Think Escape party bus or limo and be whisked away to San Francisco's hottest nightclubs where VIP treatment brings all party bus guests to the front of the line. Planning the perfect night on the town is easy with Think Escape's fleet of luxury buses and extended vehicles, each with different amenities for socializing and transport. Think Escape's Bay Area party bus rentals include free entry into selected exclusive nightclubs, professional hostess and chauffer, in-vehicle coolers stocked with amenities for a perfect night of partying.
Alcatraz Lunch Cruise
The Alcatraz Lunch Cruise is a luxurious way to get to see some of San Francisco’s favorite sights. A gourmet lunch buffet features options like asiago Caesar salad, bay shrimp salad, roasted chicken, garlic-herb roasted new potatoes and more. While guests enjoy lunch, they can take in views of San Francisco Bay’s flora and fauna, Angel Island and Alcatraz, and a live narration explores the history of Alcatraz. Please note that this tour doesn’t stop on Alcatraz Island.
Luxury Catamaran Sailing Cruise
A relaxing way to explore the San Francisco Bay is with the Luxury Catamaran Sailing Cruise. A drink bar and snacks are available for travelers’ enjoyment as they travel under the Golden Gate Bridge, around Alcatraz Island and even past a colony of sea lions. This is a peaceful San Francisco cruise option for families, and children under 5 ride for free.
City Kayak, located on San Francisco's Embarcadero close to the San Francisco Giant's ATT Park, offers a great way to experience San Francisco from Bay level, a point of view and a unique experience you'll not soon forget.
Think Escape Casino Tour
San Francisco Bay Area
San Franciscans may be familiar with Think Escape's party buses that shuttle the late-night crowds to and from various city nightclubs, but the Cache Creek Casino Escape is a little-known gem among Bay Area destinations. With personal charter service on the luxurious Fantasy Limo Bus to Cache Creek Casino and Resort, the Cache Creek Casino Escape tour is a smart choice for San Franciscans looking for a little gaming fun or planning a large group activity
The Newark Museum, in Newark, Essex County, is the state's largest museum. It holds fine collections of American art, decorative arts, contemporary art, and art from Asia, Africa, the Americas, and the ancient world. Its extensive collections of American art include works by Hiram Powers, Thomas Cole, John Singer Sargent, Albert Bierstadt, Frederick Church, Childe Hassam, Mary Cassatt, Edward Hopper, Georgia O'Keeffe, Joseph Stella, Tony Smith and Frank Stella. The Newark Museum's Tibetan galleries are considered among the best in the world. The collection was purchased from Christian missionaries in the early twentieth century.
Prudential Center is a multi-purpose indoor arena in the central business district of Newark. Opened in 2007, it is the home of the National Hockey League's (NHL) New Jersey Devils and the NCAA's Seton Hall Pirates men's basketball team. The arena seats 16,592 patrons for hockey and 18,711 for basketball. Fans and sports writers have affectionately nicknamed the arena "The Rock" in reference to the Rock of Gibraltar, the corporate logo of Prudential Financial, a financial institution that owns the naming rights to the arena and is headquartered within walking distance. In December 2013, the arena ranked third nationally and ninth internationally for self-reported annual revenue. It is located two blocks from Newark Penn Station in downtown Newark, just west of Newark's Ironbound district, making it easily accessible via New Jersey Transit, PATH, Newark Light Rail, and Amtrak.
Branch Brook Park:
Branch Brook Park is a county park of Essex County, located in the North Ward of Newark, between the neighborhoods of Forest Hill and Roseville. A portion of the park is also located within the Township of Belleville. At 360 acres, Branch Brook Park is the largest public park in the city of Newark. The park is noted for the largest collection of cherry blossom trees in the United States, with over 4,300 in more than fourteen different varieties collectively called Cherryblossomland, as well as its spectacular Cherry Blossom Festival each April. The festival attracts approximately 10,000 visitors each April. During World War II, the park's grounds served a tent city for recruits, as well as a landing strip for airplanes of the United States Postal Service. To the park’s east is the Cathedral of the Sacred Heart Basilica, one of the largest cathedrals in the United States.
Cathedral Basilica of the Sacred Heart, Newark, New Jersey:
The Cathedral Basilica of the Sacred Heart, the fifth-largest cathedral in North America, is the seat of the Roman Catholic Archdiocese of Newark. It is located at 89 Ridge Street in the Lower Broadway neighborhood of Newark, New Jersey. Envisioned as a fitting monument to the faith, construction began in 1899 and was finished in 1954. The original design called for an English/Irish-gothic church, but plans were later modified in favor of a French-gothic style. The Cathedral Basilica holds concerts open to the public throughout the year and it has the largest pipe organ ever built by the Schantz Organ Co. which includes 154 ranks playable from two consoles.